Closed loop print process adjustment based on real time feedback

ABSTRACT

In some embodiments, a photoreactive 3D printing system and methods comprise providing a system with a resin tub comprising a membrane, wherein the membrane rests on a physical tension element such that increasing downward force on the resin tub induces increasing tension on the membrane. The system also comprises a plurality of sensors comprising a resin bulk temperature sensor, and a print recipe comprising information for each layer in a 3D printed part to be built on the print platform. In some embodiments, a resin bulk temperature is measured, and the information in the print recipe, including information related to the downward force on the resin tub, is updated during a printing run based on the resin bulk temperature measurement. In some embodiments, the print recipe can be updated during a printing run based on input from at least two sensors of the plurality of sensors.

RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.16/447,654, filed on Jun. 20, 2019, and entitled “Closed Loop PrintProcess Adjustment Based On Real Time Feedback”; which claims priorityfrom U.S. Provisional Patent Application No. 62/692,196, filed on Jun.29, 2018, and entitled “Closed Loop Print Process Adjustment Based OnReal Time Feedback”; which are hereby incorporated by reference for allpurposes.

BACKGROUND

There are many types of additive manufacturing (i.e., 3D printing)systems and methods. One method utilizes photosensitive polymers (i.e.,photopolymers) that cross-link and harden from a liquid resin to a solidpolymeric material upon exposure to light. These photoreactive 3Dprinting systems typically include a resin pool, an illumination system,and a print platform, where the illumination system projects an imageinto the resin pool causing a layer of a polymeric object to be formedon the print platform. The print platform then moves the printed layerout of the focal plane of the illumination system, and then the nextlayer is exposed (i.e., printed).

Conventional photoreactive 3D printing systems operate in an open loopmanner relying on fixed process settings that cater to a general purposeuse case. This solution results in poor product performance and producesparts of low quality in a non-repeatable manner. In some cases, processadjustments are made to enable a challenging use case that, when appliedto other use cases, render the system performance well below optimal forgeneral less challenging use cases. Another conventional approach is tooptimize a specific set of printing process parameters for eachindividual print job. As the number of parameters available to optimizethe printing process is quite large, the effort required to create atuned process for each job can be extensive. The use of a trial anderror approach is often employed. The results of this approach to printprocess optimization is only marginally effective in translating into asuccessful final product as the conditions existing during the processdevelopment work are rarely present during the final part production.Additionally, since the resulting problems with part quality are notdetected during the printing process itself, subsequent print jobs andeven entire production runs may be completed with the errors goingundetected thus rendering all output as scrap and the machine time aslost work. In many cases, there is also a trade-off between printingspeed and printed object quality, which is difficult to optimize fordifferent use cases.

SUMMARY

In some embodiments, a method comprises providing a photoreactive 3Dprinting system, the system comprising: a chassis; an elevator systemmovably coupled to the chassis, wherein the elevator system compriseselevator arms; a print platform mounted to the elevator arms; a resintub, wherein the resin tub comprises a membrane, and the membrane restson a physical tension element such that increasing downward force on theresin tub induces increasing tension on the membrane; a membrane tensionapparatus which applies a downward force on the resin tub; a resin poolconfined by the resin tub and the membrane; an illumination system; aplurality of sensors comprising a resin bulk temperature sensor; and aprint recipe comprising information for each layer in a 3D printed partto be built on the print platform. The print recipe comprises one ormore of build geometry, illumination energy, exposure time per layer,wait time between layers, print platform position, print platformvelocity, print platform acceleration, resin tub position, resin tubforce, resin chemical reactivity, and resin viscosity. The methodfurther comprises: projecting an image through the membrane and focusedat a polymer interface located within the resin pool using theillumination system; moving the print platform in a z-direction with theprint platform velocity and the print platform acceleration using theelevator system; applying a downward force to the resin tub to induce amembrane tension on the membrane; measuring a resin bulk temperatureusing the resin bulk temperature sensor; and updating the print platformvelocity and the print platform acceleration in the print recipe duringa printing run based on the resin bulk temperature of the resin pool.

In some embodiments, a photoreactive 3D printing system comprises: achassis; an elevator system movably coupled to the chassis, wherein theelevator system comprises elevator arms; a print platform mounted to theelevator arms; a resin tub, wherein the resin tub comprises a membrane,and the membrane rests on a physical tension element such thatincreasing downward force on the resin tub induces increasing tension onthe membrane; a membrane tension apparatus which applies a downwardforce on the resin tub; a resin pool confined by the resin tub and themembrane; an illumination system; a plurality of sensors; and a printrecipe comprising information for each layer in a 3D printed part to bebuilt. The plurality of sensors comprises at least two of: a z-stageposition sensor; a z-stage velocity sensor; a resin tub verticaldisplacement sensor; an elevator arm load sensor; an accelerometer; aresin bulk temperature sensor; and a thermal imaging system. The printrecipe comprises one or more of build geometry, illumination energy,exposure time per layer, wait time between layers, print platformposition, print platform velocity, print platform acceleration, resintub position, resin tub force, resin chemical reactivity, and resinviscosity. The print recipe is updated during a printing run based oninput from at least two sensors of the plurality of sensors.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1D are simplified schematics in perspective views of examplephotoreactive 3D printing systems (PRPSs), in accordance with someembodiments.

FIG. 1E is a simplified schematic in perspective view of a PRPS withfour image projectors and a composite image with four sub-images, inaccordance with some embodiments.

FIG. 1F shows three simplified schematics in perspective views of a PRPSwith two image projection systems, in accordance with some embodiments.

FIG. 1G is a simplified schematic of a portion of a PRPS in perspectiveview with four image projection systems, in accordance with someembodiments.

FIGS. 1H-1K are simplified schematics of moving light sources or movingoptical systems to form composite images made up of moving sub-images,in accordance with some embodiments.

FIG. 1L is a simplified schematic of multiple PRPSs in a singleenclosure, in accordance with some embodiments.

FIG. 1M is a simplified schematic of an automated resin dispensingsystem for one or more PRPSs, in accordance with some embodiments.

FIGS. 2A-2B are simplified schematics in vertical cross-sectional andperspective exploded views, respectively of examples of resin tubs,membranes, and membrane tension apparatuses for PRPSs, in accordancewith some embodiments.

FIG. 3 is a simplified schematic in vertical cross-sectional view ofexamples of thermal imaging systems for PRPSs, in accordance with someembodiments.

FIG. 4 is a simplified graph showing an example of illumination energyfor a plurality of pixels, in accordance with some embodiments.

FIGS. 5 and 6 are flowcharts of methods for closed loop feedback inPRPSs, in accordance with some embodiments.

DEFINITIONS

In the present disclosure, the following terms shall be used.

Resin: Generally refers to a monomer solution in an uncured state.

Resin Pool: Volume of resin contained within a Resin Tub, immediatelyavailable for a Print Job.

Resin Tub: Mechanical assembly incorporating a membrane and which holdsthe resin pool.

Print Platform (i.e., Print Tray): System attached to the elevator uponwhich the resin is cured and the physical part (i.e., printed object) isbuilt.

Elevator system: System of parts that connect the Z-Stage to the PrintPlatform.

Z-Stage: Electro-mechanical system that provides motion to the ElevatorSystem.

Polymer Interface: The physical boundary of the Resin Pool and the ImageDisplay System's focal plane.

Membrane: Transparent media creating the Polymer Interface, generallyoriented parallel to the XY plane.

Build Area: Area of the XY plane that can be physically addressed by theImage Display System.

Intra-Print: Context of events that can occur between the start and thefinish of a single Print Job.

Inter-Print: Context of events that can happen both Intra-Print andoutside the Intra-Print context.

Print Job (i.e., Print Run): Sequence of events initiated by the first,up to and including the last command of a 3D print.

Print Process Parameters (PPPs): Input variables that determine thesystem behavior during a Print Job.

Print Process: Overall print system behavior as governed by the PrintProcess Parameters.

Polymerization: Chemical reaction by which the liquid monomertransitions to a solid polymer.

Curing: Same as polymerization.

Layer Move: A move of the Print Platform in the Z axis betweensuccessive exposures of the Image Display System (where the orientationof the Z axis is similar to that shown in the example in FIG. 1A).

Recharge Move (i.e., Pump Move): A move of the Print Platform that isgreater than a Layer Move to allow Resin to be replenished at thePolymer Interface.

Exposure Time: Temporal duration during which energy is transferred tothe Polymer Interface.

Irradiance: Radiant power, per unit area, incident upon a surface, i.e.,the Polymer Interface.

Pixel: Smallest subdivision of the build area XY plane where Irradiancecan be directly manipulated (where the orientation of the XY plane issimilar to that shown in the example in FIG. 1A).

Image Display System: Combination of electronics and optics that enablesPixel level manipulation of Irradiance, at the Polymer Interface, overthe Build Area.

Illumination System: Combination of electronics and radiant emissionsources that can be controlled by the Image Display System to adjust theIrradiance delivered to the Polymer Interface.

Closed Loop: Utilizing sensor feedback to automate performanceadjustment of a “system” based on the optimal relationship between the“input” and the “output.”

DETAILED DESCRIPTION

Disclosed herein are embodiments for closed loop feedback inphotoreactive 3D printing systems (PRPSs). In some embodiments, PRPS areequipped with one or more sensors that monitor various parametersbefore, during, and/or after a print run. In some cases, the informationfrom the sensors is used to alter the printing process during the printrun, and thereby operate in a closed loop manner. Closed loop operation,as described by the systems and methods herein, can be beneficial for avariety of reasons, including improved print quality (e.g., printedobject structural integrity, and object surface roughness), print runduration, and equipment longevity. Manufacturing efficiency and costeffectiveness of the system, as well as system maintenance andserviceability, can also be improved using the systems and methodsdescribed herein.

In some embodiments, the PRPSs described herein contain a plurality ofsensors integrated into closed loop feedback systems, which enableimproved (or optimal) printing efficiency over a broad range ofoperating variables without the need for manual intervention or highlyspecialized process profiling. This is in stark contrast to conventionalsystems, which typically operate in an open loop manner relying on fixedprocess settings that cater to a general purpose use case.

In some embodiments, two or more sensors are integrated in a closed loopfeedback system in a PRPS, to provide information to adjust parametersof a print run in situ. The relationships between different inputparameters (e.g., illumination energy, membrane tension, and printplatform movement) and output parameters (e.g., local resin temperature,and force experienced by the print platform during movement) duringprinting are not recognized or utilized in conventional systems. Therelationships between the different parameters can be complex, and basedon insights that are non-intuitive. For example, the curing of the resinis an exothermic process, which causes the resin temperature to increasethroughout a run, which can negatively impact the print qualitythroughout the print run. Compounding the complexity, in some cases theresin reactivity is also a function of temperature. For example, in somecases the resin can react more quickly at higher temperatures. Sinceprinting different objects requires different amounts of illuminationenergy per layer and in different patterns, the temperature rise of theresin both globally and locally will be different for each printedobject. Using the systems and methods described herein, complexinteractions between multiple input and output parameters, like the onesdescribed above, can be measured and accounted for during a print run,resulting in higher quality printed objects.

Systems and methods relating to PRPSs that include multiple imageprojection systems and/or image correction for various factors (e.g.,resin reactivity, uniformity and alignment) are described morecompletely in U.S. patent application Ser. No. 16/370,337, the entiretyof which is incorporated herein by reference. The systems and methodsdescribed in U.S. patent application Ser. No. 16/370,337 can be used inconjunction with the closed-loop feedback systems and methods describedherein.

In some embodiments, the PRPSs described herein contain a 3D printengine, embedded system electronics, and a multitude of sensors (e.g.,force gauges, position encoders, proximity/presence detection sensors,viscosity sensors, temperature/humidity sensors, accelerometers, lightarray sensors, etc.). All sensors can continuously and/or periodicallyacquire their respective data, which can be fed-back into the embeddedsystem electronics. The embedded system electronics can process the datafrom the (one or more) sensors and compensate or adjust driving elementsin the 3D print engine, in real time during printing, to optimize printquality and/or printing speed.

In some embodiments, a print recipe is used by the PRPS. The printrecipe contains information for each layer in a 3D printed part to bebuilt by the PRPS. The print recipe can contain instructions for thePRPS before, during and after a print run. For example, the print recipecan include parameters and instructions related to build geometry,illumination energy, exposure time per layer, wait time between layers,print platform position, print platform velocity, print platformacceleration, resin tub position, resin tub force, resin chemicalreactivity, and resin viscosity. In conventional systems, the printrecipe is pre-determined before a print run, and is static (i.e., itdoes not change during the print run). In the PRPSs and methodsdescribed herein, the print recipe can be updated before, during and/orafter the print run. For example, the parameters and/or instructionscontained within the print recipe can be updated before, during and/orafter the print run based on input from one or more sensors in the PRPS.In some embodiments, the print recipe can also be updated before, duringand/or after the printing of a given layer within the printed object.

Print quality can be affected by many different internal and externalfactors. Some non-limiting examples of factors that can affect printquality in PRPS include items such as resin reactivity and itstemperature dependency, resin viscosity and its temperature dependency,irradiance level and its variation with multiple factors, print platformmove speed, membrane tension, print platform move accuracy, oxygendepletion rates within the resin pool, printed part geometry, andprinted object to membrane delamination forces. The overall part qualitycan be evaluated by printed object spatial accuracy, structuralintegrity (e.g., layer to layer adhesion, etc.), mechanical properties,surface finish, and other qualities of a printed object, all of whichcan be improved by implementation of the systems and methods describedherein.

FIGS. 1A-1D illustrate an example of a PRPS 100, in accordance with someembodiments. The PRPS 100 shown in FIGS. 1A-1D contains a chassis 105,an image projection system (i.e. an “illumination system”) 110, adisplay subsystem (i.e., an “image display system”) 115, a resin pool120, a polymer interface 125, a resin tub 130, a membrane 135, a printplatform 140, an elevator system 145, elevator arms 150, a z-stage 155,a build area 160, and a membrane tension apparatus 165. The operation ofthe example PRPS 100 shown in FIGS. 1A-1D will now be described.

The chassis 105 is a frame to which some of the PRPS 100 components(e.g., the elevator system 145) are attached. In some embodiments, oneor more portions of the chassis 105 is oriented vertically, whichdefines a vertical direction (i.e., a z-direction) along which some ofthe PRPS 100 components (e.g., the elevator system 145) move. The printplatform 140 is connected to the elevator arms 150, which are movablyconnected to the elevator system 145. The elevator system 145 enablesthe print platform 140 to move in the z-direction (as shown in FIG. 1A)through the action of the z-stage 155. The print platform 140 canthereby be lowered into the resin pool 120 to support the printed partand lift it out of the resin pool 120 during printing.

The illumination system 110 projects a first image through the membrane135 into the resin pool 120 that is confined within the resin tub 130.The build area 160 is the area where the resin is exposed (e.g., toultraviolet light from the illumination system) and crosslinks to form afirst solid polymer layer on the print platform 140. Some non-limitingexamples of resin materials include acrylates, epoxies, methacrylates,urethanes, silicone, vinyls, combinations thereof, or otherphotoreactive resins that crosslink upon exposure to illumination.Different photoreactive polymers have different curing times.Additionally, different resin formulations (e.g., differentconcentrations of photoreactive polymer to solvent, or different typesof solvents) have different curing times. In some embodiments, the resinhas a relatively short curing time compared to photosensitive resinswith average curing times. In some embodiments, the resin isphotosensitive to wavelengths of illumination from about 200 nm to about500 nm, or to wavelengths outside of that range (e.g., greater than 500nm, or from 500 nm to 1000 nm). In some embodiments, the resin forms asolid with properties after curing that are desirable for the specificobject being fabricated, such as desirable mechanical properties (e.g.,high fracture strength), desirable optical properties (e.g., highoptical transmission in visible wavelengths), or desirable chemicalproperties (e.g., stable when exposed to moisture). After exposure ofthe first layer, the print platform 140 moves upwards (i.e., in thepositive z-direction as shown in FIG. 1A), and a second layer can beformed by exposing a second pattern projected from the illuminationsystem 110. This “bottom up” process can then be repeated until theentire object is printed, and the finished object is then lifted out ofthe resin pool 120.

In some embodiments, the illumination system 110 emits radiant energy(i.e., illumination) over a range of different wavelengths, for example,from 200 nm to 500 nm, or from 500 nm to 1000 nm, or over otherwavelength ranges. The illumination system 110 can use any illuminationsource that is capable of projecting an image. Some non-limitingexamples of illumination sources are arrays of light emitting diodes(LEDs), liquid crystal based projection systems, liquid crystal displays(LCDs), liquid crystal on silicon (LCOS) displays, mercury vapor lampbased projection systems, digital light processing (DLP) projectors,discrete lasers, and laser projection systems.

In some embodiments, the illumination systems (i.e., the imageprojection systems) of the PRPSs described herein (e.g., as shown inelement 110 of the PRPS in FIGS. 1A-1D) contain a plurality of imageprojectors configured in an array. This can be advantageous to cover alarge printing area with a high resolution of build element pixelswithout sacrificing print speed. FIG. 1E shows a simplified schematicexample of a PRPS containing four image projectors 170 a-d configured toproject four sub-images 180 a-d to form a single composite image overbuild area 160. FIG. 1E shows an example where the illumination systemsare projection based systems, however, in other embodiments, theillumination systems can be projection or non-projection based systemsincluding those that contain arrays of light emitting diodes, liquidcrystal based projection systems, liquid crystal displays (LCDs), liquidcrystal on silicon (LCOS) displays, mercury vapor lamp based projectionsystems, digital light processing (DLP) projectors, discrete lasers, andlaser projection systems.

FIG. 1F shows three perspective schematics of a non-limiting example ofa PRPS with two image projection systems 110 a-b. The other componentsof the PRPS shown in FIG. 1F are similar to those shown in FIGS. 1A-1D,and some components of the PRPS are not shown in the system in FIG. 1Ffor clarity. The resin tub 130 a and build area (not shown) within theresin tub are about twice as large as in the PRPS shown in FIGS. 1A-1D,which is enabled by using two image projection systems 110 a-b ratherthan one.

FIG. 1G shows a non-limiting example of a portion of a PRPS with fourimage projection systems 110 c-f. In this example, the four imageprojection systems are arranged in a 2×2 array. In other embodiments, aPRPS has multiple image projection systems, which are arranged in an N×Marray, where N is the number of image projection systems in onedirection of the array and M is the number of image projection systemsin another direction of the array, where N and/or M can be from 1 to 5,or 1 to 10, or 1 to 20, or 1 to 100, or 2, or 5, or 10, or 20, or 100.FIG. 1G shows four image projection systems 110 c-f configured toproject four sub-images 190 c-f, respectively, to form a singlecomposite image over build area 160 a. FIG. 1G also shows that thesub-images overlap in this example.

In some embodiments, the build area is from 100×100 mm² to 1000×1000mm², or from 100×100 mm² to 500×500 mm², or from 100×1000 mm² to500×1000 mm², or square or rectangular ranges in between the previousranges, or larger than 1000×1000 mm². In some embodiments, thesub-images projected from an array of image projectors each have an areathat is from 50×50 mm² to 200×200 mm², or from 50×50 mm² to 150×150 mm²,or from 50×100 mm² to 100×200 mm², or from 50×50 mm² to 150×150 mm², or192 mm×102.4 mm, or 134.4 mm×71.68 mm. In some embodiments, the areacovered by each sub-image is approximately rectangular, square,circular, oval, or other shape. In some embodiments, each imageprojector projects light with maximum or average power densities from 5mW/cm² to 50 mW/cm², or from 10 mW/cm² to 50 mW/cm², or from 5 mW/cm² to20 mW/cm². In some embodiments, the exposure time of each pixel or layeris from 0.05 s to 3000 s, or from 0.08 s to 1500 s, or from 0.08 s to500 s, or from 0.05 s to 1500 s.

In other embodiments, the PRPSs described can contain one or moreillumination systems that are capable of projecting images in more thanone print area. Some examples of this are, illumination systems that aremounted on moving gantries (e.g., providing lateral movement, orpivoting movement), or that contain an optical system (e.g., usingmirrors) that enable the projected image to be focused in differentprint areas. Such moving illumination systems can be advantageous tocover a large printing area with a high resolution of build elementpixels while minimizing the number of illumination systems (i.e.,minimizing equipment cost).

In some embodiments, the movement of the image projectors includesmoving the light source of the image projector (e.g., such as an LED orlamp). In some embodiments, the light source moves by translation (e.g.,along a plane that is roughly parallel to the plane of the build area).FIG. 1H shows a non-limiting example of a composite image made up ofsub-images 1010 a-c, where the light source 1012 moves by translation inthe direction 1005. In some embodiments, the light source moves bytranslation and the direction of translation (e.g., 1005 in FIG. 1H) isapproximately parallel to the plane of the build area. In such cases,each image can be calibrated for position, and other corrections, asdescribed further herein.

In some embodiments, the light source will move by tilting and/orrotating the light source around one or more axes of rotation. FIG. 1Ishows a non-limiting example of a composite image made up of sub-images1020 a-c, where the light source 1022 moves by rotation in the direction1006. In some embodiments, the direction of rotation (e.g., 1006 in FIG.1I) has an axis of rotation that is approximately parallel to the planeof the build area. In cases where the image projectors rotate, theposition and other corrections such as warp and skew, as describedfurther herein, can be accounted for.

In some embodiments, the light source for the image projectors will bestationary and the projected sub-images will move through the use ofmoving optical systems (e.g., moving mirrors, or moving lenses). In someembodiments, the optical systems will move by translation (e.g., along aplane that is roughly parallel to the plane of the build area), or bytilting and/or rotating the optical systems around one or more axes ofrotation. FIG. 1J shows a non-limiting example of a composite image madeup of sub-images 1030 a-c, where the light source 1032 is stationary,and a mirror 1034 moves by rotation in the direction 1007 to project thesub-images 1030 a-c. Alternatively, FIG. 1K shows a non-limiting exampleof a composite image made up of sub-images 1040 a-c, where the lightsource 1042 is stationary, and a lens 1044 moves by rotation in thedirection 1008 to project the sub-images 1040 a-c. In different cases ofmoving optical systems (e.g., those shown in FIGS. 1J and 1K), eachprojected image can be calibrated for position, warp and skew, and/orother corrections, as described further herein.

The non-limiting examples in FIGS. 1H-1K contain systems with one movingimage projector, or one stationary image projector and one movingoptical system (e.g., a mirror or lens). In other embodiments, the PRPSsdescribed herein can contain more than one image projector and oroptical system, and the image projectors and/or optical systems move toproject a plurality of sub-images onto a build area. In these cases, themultiple image projectors and/or optical systems can all move bytranslation or rotation. In some embodiments, the PRPS containssub-systems to enable each image projector and/or sub-image to moveindependently. In other embodiments, the PRPS contains sub-systems toenable all of the image-projectors and/or sub-images to move as a group.In some embodiments, the image projector(s) and/or optical system(s) canboth translate and rotate to project sub-images at different locationswithin a build area.

Systems and methods relating to PRPSs including systems with multipleimage projections systems, moving image projectors, and/or movingoptical systems are described more completely in U.S. patent applicationSer. No. 16/370,337, the entirety of which is incorporated herein byreference.

FIG. 1L shows a simplified schematic of multiple PRPSs 1052 a-ccontained within a single enclosure 1050, in accordance with someembodiments. Enclosure 1050 can maintain a controlled environment (e.g.,air pressure, temperature, and/or humidity), isolate the PRPSs fromexternal forces (e.g., ground motion), and house centralized systemsshared by the multiple PRPSs. For example, enclosure 1050 can containcentralized control software capable of controlling multiple PRPSs 1052a-c in the enclosure 1050, a centralized robot that can interact withmultiple PRPSs 1052 a-c in the enclosure 1050, and other types ofcentralized systems and components, such as resin tanks for automatedresin dispensing systems.

FIG. 1M is a simplified schematic of an automated resin dispensingsystem 1060 for PRPSs, in accordance with some embodiments. The examplein FIG. 1M includes an automatic resin dispenser 1054, which candispense resin from resin vats 1056 a-c into the resin tubs of PRPSs1052 a-c. This example shows a single dispenser 1054 feeding resin fromthree resin vats 1056 a-c to three PRPS 1052 a-c, however, in differentembodiments, from 1 to 10 dispensers can feed resin from 1 to 10 resinvats to 1 to 20 PRPSs. For example, one or more PRPSs can be fed usingan automated resin dispensing system where each PRPS can have a singlededicated resin vat and dispenser, or each PRPS can have a dedicateddispenser feeding resin to the PRPS from one or more resin vats. It canbe advantageous to have each PRPS have a dedicated dispenser and resinvat, for example, if different types of resins are used in the differentPRPSs, then having dedicated resin dispensing systems can prevent resincross-contamination. An enclosure (not shown) is used around the PRPSsand/or resin vats, in some embodiments.

The example system shown in FIGS. 1A-1D and the PRPSs shown in FIGS.1E-1M, are non-limiting examples only, and variations on these designscan be made in accordance with some embodiments described herein. Forexample, other PRPSs can be inverted with respect to the system shown inFIGS. 1A-1G. In such “top down” systems, the illumination source isabove the resin pool, the print area is at the upper surface of theresin pool, and the print platform moves down within the resin poolbetween each printed layer. The closed loop feedback systems and methodsdescribed herein are applicable to any PRPS configuration, includinginverted systems. In some cases, the geometry of the sensor or feedbacksystem can change to accommodate a different PRPS geometry, withoutchanging the fundamental operation of the closed loop systems within thePRPS.

In some embodiments, additional systems (not shown in FIGS. 1A-1G) areincluded in the PRPSs described herein to move the resin within theresin pool. For example, the PRPSs described herein can include one ormore resin circulation systems (e.g., a system with inlets, outlets andpumps to flow the resin in and out of the resin tub, or a physical mixerwithin the resin pool to mix the resin within the pool, or a wiper tomove resin away from the membrane within the resin pool). Such resincirculation systems can be continuous or intermittent, can reduce thethermal gradients within the resin pool, and/or can provide fresh resinto the membrane (i.e., the print area), either before, during, and/orafter a print run in response to one or more feedback parametersmeasured in the present systems and methods.

FIG. 2A shows an example of a resin tub 130 and a unique membranetensioning system with resin tub vertical displacement sensors 210,which can be used in closed loop feedback systems in the present PRPSs,in accordance with some embodiments. In conventional systems, membranetension can be fixed and set in the resin tub at the time the resin tubis assembled. However, this only allows for a predefined amount oftension that is static and non-adjustable. In the system shown in FIG.2A, the membrane tension can be adjusted at any point during or betweenprints, where the adjustment can be made automatically in response tofeedback information from one or more sensors 210. As depicted in FIGS.2A and 2B, in some embodiments, the perimeter of the resin tub membrane135 is attached to the resin tub 130, and the membrane 135 rests on aphysical tension ring 220 such that a downward force (or load) “F” onthe tub is applied to the membrane-tension ring contact interface thuscausing the membrane to be placed in a state of increasing tension withincreasing downward force F. The tension in the membrane can then be setto a desired level by applying a certain amount of down force based on apre-determined tension-force relationship. The desired level of membranetension can be based on, for example, material properties of themembrane, print speed, system construction (e.g., if membrane issupported from below or not), resin viscosity, and/or printspecifications (e.g., tolerance ranges of the printed part).

Position sensors 210, used to collect information about the vertical(i.e., z-axis) displacement 230 of the resin tub 130, provide feedbackregarding the vertical displacement 230 of the resin tub 130 andindicate if the system is capable of supporting the required tension orif the membrane 135 has reached a critical, end of life, condition. Forexample, as described above, as the membrane 135 ages it will experiencecreep, and the resin tub vertical displacement 230 will change for agiven amount of applied down force F. The vertical displacement 230 ofthe resin tub 130 is also dependent on the resin tub 130 down force F.This load F can be applied by the membrane tension apparatus eitherpneumatically or mechanically through many different mechanisms. In thenon-limiting example shown in the PRPS in FIGS. 1A-1G and 2A-2B, apneumatic cylinder apparatus 165 is employed to apply the force F to theresin tub 130. In some embodiments, the load F is monitored via sensors210 in the down force mechanism, and the force feedback, the tubdisplacement feedback, and the previously determined tension-forcerelationship, are used to adjust the membrane tension at any pointduring a print job. In other embodiments, the membrane tension apparatususes motors (e.g., stepper motors) and linear encoders to apply the downforce F to the resin tub 130. In some embodiments, the membrane tensionsystem is used to release (or reduce) tension from the membrane when notin active printing use (i.e., active printing mode) thus prolonging theuseful life of this critical element.

FIG. 2A also shows a simplified cross-section schematic optional tensionring load cells 240 and membrane displacement load sensors 250. Thetension ring load cells 240 are attached beneath tension ring 220, andprovide off-line and real-time information regarding the force on thetension ring. This information can also be used to control the load Fapplied to the resin tub 130. The membrane displacement load sensors 250are attached beneath the resin tub 130 and can provide off-line andreal-time information regarding the force on the resin tub 130, whichcan also be used to control the load F applied to the resin tub 130. Insome embodiments, sensors 210, 240 and 250 are all used in concert tocontrol the membrane tension system, and also provide redundancy, whichis useful to detect part failures (e.g., membrane creep, or pneumaticcylinder malfunction).

FIG. 2B shows a schematic in perspective view of an example of amembrane tension apparatus for a PRPS, in accordance with someembodiments. The example shown in FIG. 2B contains a resin tub 130, amembrane 135, a physical tension element (i.e., a tension ring) 220, atension mechanism 165, and a print chassis 105. In the example apparatusshown in FIG. 2B, the membrane 135 is affixed to the resin tub 130 toform a container that is capable of holding the resin pool (not shown).In this example, the resin tub 130 with membrane 135 affixed is placedon the tension ring 220, and the tension mechanisms 165 are in contactwith the resin tub 130. When the membrane 135 rests on the tension ring220, the tension mechanism 165 (pneumatic cylinders in the exampleshown) can apply a down force F to the resin tub 130, which will stretchthe membrane 135 over the tension ring 220. In this example, therefore,an increasing down force F applied to the resin tub 130 by the tensionmechanisms 165 will increase the tension in the membrane 135. The buildarea (not shown), in this example, is smaller than the inner dimensionsof the tension ring 220. In some embodiments, load cell(s) 240 shown inFIG. 2A can be mounted and appropriately positioned on print chassis 105to measure localized downward force exerted by tension ring 220, resintub 130, or by a combination thereof. Similarly, the displacementsensor(s) 250 shown in FIG. 2A can be mounted and appropriatelypositioned on print chassis 105 to measure displacement between resintub 130 and its corresponding cavity in print chassis 105.

In some embodiments, a transparent plate (e.g., glass) (not shown) isaffixed to the tension ring 220. In some embodiments, the transparentplate is flush with the top of the tension ring 220 (i.e., the part ofthe tension ring that makes contact with the membrane) and supports themembrane 135 from below. In other embodiments, a transparent plate islocated above the top of the tension ring 220 and supports the membrane135 from below. In still other embodiments, a transparent plate islocated below the top of the tension ring 220 and supports the membrane135 in the case of large deflections. In some embodiments, it isadvantageous to have the transparent plate below the top of the tensionring 220. Not to be limited by theory, in some embodiments where thetransparent plate is located below the top of the tension ring 220, moreair (or oxygen) will permeate the membrane 135 (compared to embodimentswhere the glass is at or above the top of the tension ring and in directcontact with the membrane 135) and be absorbed by the resin adjacent tothe membrane 135. The absorbed air (or oxygen) will reduce the curingrate of the resin adjacent to the membrane 135 and reduce theprobability of the resin adhering to the membrane 135.

In different embodiments, sensors of the present PRPSs can include oneor more of a z-stage position sensor, a z-stage velocity sensor, az-stage acceleration sensor, a resin tub vertical displacement sensor,an elevator arm load sensor, an accelerometer, a resin bulk temperaturesensor, a thermal imaging system, and illumination system sensors.

Referring again to FIG. 1A, non-limiting examples of sensors integratedinto an example PRPS are shown. An accelerometer 10 is shown attached toan upper portion of the chassis 105 that can measure local accelerationof the PRPS in various directions (e.g., due to ground movement, orother external force). A gyroscope (or accelerometer, or level sensor)15 is also shown attached to the chassis 105 that can measure globalacceleration (in various directions) or tilt of the PRPS. The PRPS inFIG. 1A also contains a radiant power sensor 20, which is embeddedwithin the illumination path of optics in the image projection system110, capable of measuring the intensity of the output from anillumination source within the image projection system 110.

Continuing with FIG. 1A, the PRPS can contain several image sensors tomeasure different properties of the membrane 135, the build area 160, orregions adjacent to the membrane 135 and/or build area 160. For example,the PRPS in FIG. 1A contains a thermal image sensor 25, which ispositioned to image a region near the build area 160, that can measurethe temperature distribution of the resin in the proximity of the buildarea 160 within the resin tub 130. The PRPS in FIG. 1A also contains asecond image sensor (or capture device) 30, which is also positioned toimage a region near the build area 160, that can measure any wavelengthsof electromagnetic radiation.

The image sensors 25 and/or 30 in the present PRPSs can acquire highresolution images (e.g., with one or more pixels of detected resolutionper actual pixel area in the build area), or low resolution images. Insome cases, the image sensors 25 and/or 30 acquire low resolutionimages, which are subsequently up-sampled. For example, low resolutionimages can be up-sampled using Single Image Super Resolution (e.g., withartificial intelligence, or deep learning) up-sampling. Up-sampling lowresolution images can help detect issues (or anomalies) with imagesdisplayed on the build area, and send information back to the PRPS toadjust the print recipe content in real-time. Acquiring low resolutionimages is advantageous because it reduces the cost of the image sensorcomponents (e.g., an inexpensive web-cam low resolution camera can beused instead of a more expensive high resolution (e.g., 1080×1920) imagesensor).

The second image sensor(s) 30 can be used to provide spectral orhyperspectral information (i.e., at single wavelengths or multiplewavelengths to provide measured spectra), for example, measurements ofthe projected image, the resin properties, temperature distributions,and/or the presence of foreign contaminants. The second image sensor 30can detect wavelengths in any range, for example, IR (e.g., using athermal imaging camera), UV (e.g., in the wavelength of the imageprojection system 110), or visible (e.g., using an RGB camera).

For example, second image sensor 30 can be an image sensor capable ofdetecting the wavelength output from the image projection system 110(e.g., a UV wavelength of light used to expose the resin), and can beused to provide off-line or real-time feedback regarding the accuracy ofthe projected image in the build area 160 (or in a region adjacent tothe build area 160). In some cases, a low-cost camera (e.g., a webcam)is capable of detecting the wavelength output from the image projectionsystem 110, and can be used to capture images of the membrane or buildarea from below (e.g., by pointing the camera at the bottom-side of theresin tub) to check if the projected layer images are being projected asexpected. The captured images can be displayed in visible light colorsfor an operator to monitor during a print job. In some cases, computervision can be employed to analyze the captured images and detect ifthere is a problem with the projection system or image display subsystem(e.g. problems with the hardware, corrupted file data content, etc.)early before wasting resin and time on an erroneous part. In someembodiments, the information from the second image sensors 30 can beprocessed (e.g., using computer vision) and fed back to the PRPS toadjust the print recipe during a print run (e.g., by adjustingproperties of the projected image based on measurements from sensor 30until the measurements match expected values).

In some cases, second image sensor 30 can detect light in the IRwavelengths (or UV or visible wavelengths) to determine if there is dustor debris in the optical path between the image projector and themembrane. Such a sensor could be used in combination with a dedicatedprojector to detect dust or debris in the optical path between the imageprojector and the membrane. An image sensor or sensors 30 capable ofresolving a plurality of energy wavelengths, for example from UV tovisible, or UV to IR, or visible to IR, can be employed to detectforeign contamination between the print glass and the membrane, orcontamination in the resin tub that has settled on the membrane. Forexample, an expected displayed image can be compared against an imagecaptured from the capture device(s) 30 to detect the presence of debris.In some cases, multiple image spectra may be employed to detectdifferent types of contamination, such as solid particles and/or curedresin contaminants from previous builds.

In another example, the second image sensor 30 can be an image sensorcapable of detecting a spectrum (e.g., 100 nm to 20 microns) thatprovides information regarding the presence of cured and uncured resin(e.g., by detecting the presence of cross-links), and can be used toprovide real-time feedback regarding the amount and distribution ofcured versus uncured resin in the build area 160 (or in a regionadjacent to the build area 160). Such a sensor 30 could also be used todetermine if cured resin is near the membrane, for example, due to curedresin breaking off of the part being printed. In another example, thesecond image sensor 30 can be an image sensor capable of detecting aspectrum (e.g., 100 nm to 20 microns) that provides informationregarding other properties of the resin, such as if the resin hasdegraded over time, the presence of water, and/or the presence of otherforeign contaminants in the resin.

Referring again to FIG. 1B, additional non-limiting examples of sensorsintegrated into an example PRPS are shown. A linear encoder strip 35 isplaced on a vertical (i.e., z-direction, as shown in FIG. 1A) portion ofthe chassis 105, and a linear encoder sensor 40 is attached to theelevator system 145. The linear encoder sensor 40 is coupled to thelinear encoder strip 35, such that when the elevator system 145 moves inthe vertical direction the linear encoder sensor 40 can provide off-lineor real-time information regarding the elevator system 145 positionrelative to the linear encoder strip 35. Such real-time information canbe used, for example, to provide feedback regarding the actual layerthicknesses being printed during a print run (e.g., accurate to a fewmicrons). If the elevator system 145 has moved slightly too far, or notenough, then the actual position information can be used to adjust theprint recipe and account for the error, for example, by applying more orless energy to the layer during exposure depending on the actual layerthickness.

Referring again to FIG. 1C, additional non-limiting examples of sensorsintegrated into an example PRPS are shown. A thermocouple (TC) 45 isshown in physical contact with the resin 120 in the resin tub 130, tomeasure the temperature of the resin. In other embodiments, a TC can belocated on the outside of the resin tub, and can be calibrated toprovide information regarding the temperature of the resin 120 in theresin tub 130. An IR temperature sensor 50 is also shown as anotherexample of a sensor that can measure the temperature of the resin 120 inthe resin tub 130. In some embodiments, the IR temperature sensor 50 iscapable of capturing an image to provide spatial information of thetemperature of the resin 120 within the resin tub 130. In otherembodiments, the IR temperature sensor 50 can only take a single point(or multiple points) of measurement, but not a whole image. The PRPS inFIG. 1C is also equipped with a resin level sensor 55, which can measurethe amount (or depth) of resin 120 in the resin tub 130. For example,such a resin level sensor 55 can be useful to measure the consumptionrate of the resin 120, and/or if any resin has broken off of a partbeing printed (which would affect the resin level as the printed part ismoved in and out of the resin 120).

Referring again to FIG. 1D, additional non-limiting examples of sensorsintegrated into an example PRPS are shown. A strain gauge 60 is shownattached to one of the elevator arms 150. In some embodiments, a straingauge 60 is placed on each of the elevator arms 150. The strain gauge 60can be used to measure the strain experienced by the elevator arms toprovide information regarding the force and/or position of the elevatorarms 150. The PRPS in FIG. 1D is also equipped with a pressure sensor 65embedded in one or more of the pneumatic cylinders of the membranetension apparatus 165. The pressure sensor 65 can provide off-line andreal-time information about the pressure the membrane tension apparatus165 is applying to the membrane 135.

Referring again to FIG. 1L, one or more environmental sensors 70 can bepositioned near one or more PRPSs to acquire environmental data such asair pressure, temperature, humidity, particle counts, smells, chemicalsin the environment, or other environmental information, and thisinformation can be used to adjust the print recipe during a print run orbetween print runs, or can be used to abort print runs. In the FIG. 1Lthe environmental sensor(s) 70 are placed within an enclosure 1050,however, in other embodiments, environmental sensor(s) 70 can be placedin a factory or other space near one or more PRPSs.

Table 1 shows some non-limiting examples of information that can beobtained from sensors (“Sensor Information”) that can be incorporatedinto the PRPS and how the information from the different sensors can beused to adjust different process parameters in closed loop feedbacksystems and methods (“Process Parameter/Action”), in accordance withdifferent embodiments.

TABLE 1 Examples of information that can be obtained from sensors in aPRPS. Sensor Information Process Parameter/Action force or load fromprint adjust print speed (also can be influenced tray (i.e., printplatform) by: resin viscosity, resin temperature, print and/or elevatorarms interface oxygen depletion rate, print interface cross-sectionalarea, current print speed, change in irradiance from UV imaging source)thermal image feedback from adjust energy density being emittedinterface between membrane and resin bulk thermal feedback from adjustpumping of resin (e.g., lower the resin pool pumped resin temperature),print speed, cooling to the resin pool, or resin circulation speedabsolute position, velocity or adjust absolute position, velocity oracceleration of the print tray acceleration of the print tray, or adjustillumination energy to account for actual layer thickness radiant powerfrom the adjust input power or exposure time illumination systemgyroscope, accelerometer, or job abortion level indicator of the printerchassis membrane tension and resin replace resin tub or change tubplacement tub position as indicators of membrane creep membrane tensionadjust pneumatic pressure in membrane tension system, or job abortionresin level abort job (e.g., if part breaks during printing)

In an example, force (or load) feedback can be obtained from a loadsensor (e.g., attached to the elevator load arm in the form of anelevator arm load sensor) to measure the amount of load experienced bythe print platform system in PRPSs. The information from this sensor canthen be used to change parameters such as the print speed. Somenon-limiting examples of factors that can influence the load experiencedby the print platform are the resin viscosity, the resin temperature,the print interface oxygen depletion rate, the print interfacecross-sectional area, the print speed, and changes in irradiance fromthe imaging source (e.g., an ultraviolet illumination system).Additionally, the print platform load feedback can be used to determineif the finished part is within acceptable limits from a mass perspectiveindicating that the completed printed part(s) is/are present on thebuild tray and is absent of any foreign or excess material. In someembodiments, during a print job, the load feedback could also determineif there was an adhesion problem and if the part has delaminated fromthe print platform. In some cases, the load feedback can also be used tounderstand excess material adhesion to the part in the form of wettedsurface area or filled in trapped voids inside the part geometry. Thiscan provide feedback on how to optimize process flow to reclaim wasteresin.

In some embodiments, the resin can contain a vertical viscositygradient, such as due to the pigments and fillers in the resin settlingover time. The PRPSs and methods described herein can also provideinformation about resin aging and vertical viscosity gradients. Forexample, the print platform can be moved through the resin pool in thevertical direction, and the position, velocity and forces experienced bythe print platform can be measured using the appropriate sensors (e.g.,position, velocity and acceleration sensors attached to the z-stage as az-stage position sensor, a z-stage velocity sensor, and a z-stageacceleration sensor, and an elevator arm load sensor), which will givesome information regarding vertical viscosity gradients within the resinpool.

In another example, thermal image feedback can be obtained from theinterface between the membrane and the resin (e.g., within the printarea) using a thermal imaging sensor to measure the local temperatureswithin the resin pool in PRPSs. The polymerization reaction tends to beexothermic and excessive heat generation can extend the polymerizationreaction past the physical boundaries desired for the geometry beingprinted. Having a thermal image map from the print area, in real time,enables the image display system to make adjustments to the energydensity being emitted to compensate for excessive energy build up inspecific spatial locations within a print layer. In some embodiments,this compensation for local temperature anomalies (e.g., hot spots) canincrease printing speed by reducing the need for excessive pump moves(i.e., recharge moves), which are slow, but help to maintain a uniformtemperature at the print interface. It also prevents unwanted materialcuring and thus improves the overall dimensional accuracy of printedparts.

FIG. 3 shows some non-limiting examples of thermal imaging systems thatcan be employed in PRPSs to detect local and/or bulk temperatures. Insome embodiments, a thermal imaging system contains a thermal imagingcamera 310 a-b, which is focused on the plane within the resin pool 120adjacent to the membrane 135 (i.e., within or adjacent to the printarea). A first embodiment in FIG. 3 shows the situation where thethermal imaging camera 310 a is offset from the axis 305 of theillumination system 110. In such a situation, image correction can beemployed to correct for the different axes between the thermal imagingcamera 310 a and the illumination system 110 and correlate a positionmeasured in the thermal image to a pixel within the print area. A secondembodiment in FIG. 3 shows a situation where a “hot mirror” 320 (i.e., amirror that reflects infrared light, and is transmissive to thewavelengths used by the illumination system (e.g., ultraviolet light))is uniquely used to align the optical path of the thermal imagescaptured by the thermal imaging camera 310 b coaxially with the opticalpath of the images projected by illumination system 110. In theembodiment of FIG. 3, the hot mirror is aligned with the optical axis305 of the illumination system 110 (i.e., aligned with the optical pathfrom the illumination system to the polymer interface), where the hotmirror 320 is angled such that the thermal imaging camera 310 b capturesimages reflected by the hot mirror 320. The coaxial alignment enabled bythe hot mirror 320 eliminates the need for image corrections required inother configurations, and can in some embodiments, provide betterthermal image resolution and more accurate correlation between thethermal image and the pixels being exposed within the print area.

In another example, bulk thermal feedback can be obtained from the resinpool in PRPSs. The bulk thermal measurement can be obtained from anyposition within the resin pool, or adjacent to the resin pool. In someembodiments, more than one bulk measurement is used to obtain a moreaccurate measurement of the bulk temperature within the resin pool, andoptionally to obtain some indication of bulk gradients within the resinpool. In this context bulk gradients are distinct from local temperaturefluctuations on the pixel length scale (e.g., which can be measured by athermal imaging system), and bulk gradients refer to larger scaletemperature fluctuations. In some embodiments, information from morethan one bulk thermal sensor within the resin pool and information froma thermal imaging system are used in combination to construct a moreaccurate temperature distribution within the resin pool. In someembodiments, during a print job, this information indicates if there isexcessive heat buildup on a macro scale. The temperature of the resincan affect the polymerization reaction rates, and if left unaccountedfor can cause part accuracy issues and/or material property issues. Inmore severe cases, unaccounted for bulk resin temperatures can lead towarping of a printed object. Monitoring this metric enables the systemto apply countermeasures such as changing the illumination energy,pumping in new resin at a lower temperature, increasing the print speed,decreasing the print speed (which is not optimal), or applying solidstate cooling directly to the resin or resin tub. In some embodiments,the system also employs a closed loop resin dispensing system where theresin is continuously circulated and maintained at an optimaltemperature.

In another example, absolute position feedback of the print tray (e.g.,from a z-stage position sensor) can be obtained. In some embodiments,the position of the print platform enables several process monitoringand quality enhancements. For example, absolute position feedbackenables real-time part geometry checking and monitoring. For example,real-time absolute position feedback of the print platform can be usedto provide information regarding the actual layer thicknesses beingprinted during a print run, which can be fed back to adjust the printrecipe and account for the error, for example, by applying more or lessenergy to the layer during exposure (e.g., by adjusting the exposuretime) depending on the actual layer thickness. In another example,absolute position feedback can determine if the system has undergone amove error or accumulated error that would result in unacceptable partquality. This condition detection, if un-correctable, could then enablethe system to abort the print job thus eliminating additional rawmaterial waste and machine time overhead. This is preferable tocompleting the errant job, which may take hours to complete, anddiscovering the failed part in subsequent process steps. In someembodiments, absolute velocity and acceleration of the print tray isobtained (e.g., from a z-stage velocity sensor, and/or a z-stageacceleration sensor), and the obtained information is employed todetermine if the print process is operating within required processcontrol limits. In some embodiments, this information is used in aclosed loop feedback system to control printing parameters such assubsequent layer print tray speeds, and illumination energies. The printplatform position, velocity and/or acceleration can also be used inconjunction with the force feedback from the print platform to ensurethat process adjustments being made intra-print are being faithfullyexecuted.

In another example, the illumination system can be outfitted with one ormore illumination system sensors and used for closed loop feedbackwithin PRPSs. The print process is highly dependent on accuratelyirradiating a pre-determined spatial pattern with a specific amount ofenergy, where the energy transfer is governed by the energy flux and thetime of exposure. Since energy emitters, such as LEDs, have outputcharacteristics that are dependent on multiple factors (e.g., inputenergy, temperature and device age), in some embodiments, the ability tomonitor the illumination system for both input and outputcharacteristics is essential. An example of an illumination systemsensor is a radiant power sensor that provides feedback within theimaging system during the print run, and enables monitoring andadjusting of the ultimate energy dose for each layer curing event.Another example of an illumination system sensor is a sensor to monitorthe thermal properties of the illumination system, such as the LEDjunction temperature, which can also provide feedback on the overallefficiency of the input power to output radiant energy conversion.Adjustments can then be made based on feedback from one or moreillumination system sensors using a highly responsive control system tomaintain optimal performance of the illumination system and improve theprinted object quality. For example, the cooling process of theillumination system can be adjusted based on thermal measurements of theillumination system, while the control system simultaneously monitorsoutput power and adjusts either input power to the illumination systemor exposure time (in the print recipe) to ensure accuracy of the totalenergy transfer to the pixels of the layer being printed. Additionally,in some embodiments, the input power to output power characteristic ofthe illumination system can be monitored (e.g., using an illuminationsystem sensor capable of measuring the output power of the illuminationsystem) over the life of the system to determine when it is no longerwithin acceptable operating limits. This allows preventative systemmaintenance and component replacement, further reducing machine downtime and the possibility of failed print jobs.

In another example, movement sensors can be used to detect kineticevents in PRPSs that could adversely affect the print quality. Somenon-limiting examples of movement sensors are a gyroscope (e.g., a ninedegree of freedom gyroscope, or gyro), an accelerometer, and/or a levelindicator. In some embodiments, movement sensors are used to detectevents that affect the whole system. For example, movement sensors candetect if the system is bumped, or if the support (e.g., table) uponwhich the system is sitting has experienced any movement (e.g., from apassing heavy vehicle). The movement sensors can be attached to any partof the system, such as the chassis. In some embodiments, thresholds canbe set that would enable a job to abort if a predetermined kinetic limit(e.g., velocity, acceleration, or displacement) is exceeded. Forexample, the movement sensor can be an accelerometer that monitorsphysical movement of the PRPS during a print run, and sends a signal toabort the print run if an acceleration is detected above a predeterminedthreshold. As previously stated, early abortion of a print job that isknown to be outside acceptable quality limits saves raw material andreduces wasted machine time. In some embodiments, different thresholdscan be applied to different types of printed objects. For example, someprinted objects (e.g., parts for aerospace or biomedical applications)are sensitive and/or have tight tolerances requiring low kinetic eventthresholds, while other printed objects (e.g., children's toys) havewider manufacturing tolerances such that more extreme kinetic events areacceptable without requiring job abortion. In some embodiments, thelevel indicator information is used in a closed loop system, engagedwith a series of adjustable position actuators, to adjust the printerorientation such that the PRPS coordinate axis is properly maintainedrelative to the fluid level in the resin tub.

In another example, PRPSs can include resin level sensors capable ofmeasuring the level of the resin in the resin tub. Some non-limitingexamples of sensors (or sensor systems) capable of measuring either thefluid/liquid level of the resin are optical sensors (e.g., using LEDs,lasers or imaging systems), ultrasonic sensors, float-type sensors, andcapacitive sensors. These resin level sensors can monitor the resinfluid level in the resin tub, which is advantageous for several reasons.Some non-limiting examples of use cases for resin level monitors includethe following. Resin level sensors can be used to determine the amountof resin consumption (e.g., by measuring the resin level before andafter a part is printed). Resin level sensors can also be used todetermine whether a part has fallen off the build platform (e.g., ifresin level suddenly spikes up, then spikes down, or a combinationthereof, then such measurements can be used to alert the system toquickly abort). Resin level sensors can also be used to determinewhether the part printed correctly or is being printed correctly (e.g.,by monitoring the rate of change of the resin level over time, or therate of resin consumption in real time). Resin level sensors can also beused to determine whether a leak or burst in the membrane occurred(e.g., if the resin level drops at a higher rate than would be expectedfrom normal printing). Resin level sensors can also be used to determinewhether resin in the resin tub is inadvertently cured by ambientlighting (e.g., if the resin level does not decrease during a print job,then the fluid level measurements can indicate that the resin in the tubwas accidentally cured into a “slab” within the resin tub).

In another example, feedback is collected from the z-stage drive system,and used in closed loop feedback systems in PRPSs. For example, thez-stage drive system can include sensors to measure the position,velocity and/or acceleration of the z-stage (and provide informationabout the position and motion of the print platform, since it isconnected to the z-stage). In some embodiments, the detected informationfrom the z-stage drive system (e.g., position, velocity and/oracceleration) enables reliability monitoring and error conditionchecking.

In another example, resin tub vertical displacement information can beobtained and used in closed loop feedback systems in PRPSs. For example,the resin tub vertical displacement can be an indicator of membranecreep. In some embodiments, excessive membrane stretch indicates resintub and/or membrane end-of-life. In other cases, the resin tub verticaldisplacement information provides feedback on the proper placement andinstallation of the resin tub, for example, as indicated by unevendisplacement around the perimeter of the tub.

In another example, as described above, pneumatic pressure is used tomaintain proper tensioning of the membrane used for the resin printinterface. Changes in membrane tension can adversely affect the printquality. Detecting excessive fluctuations in membrane tension (e.g.,using the resin tub vertical displacement sensors and/or measurements ofthe down force on the resin tub) can enable early job abortion, thuspreventing resin waste and unproductive manufacturing time. In someembodiments, regulated pressure adjustment can be used to enable activechanges to the membrane tension between print jobs and even during printjobs when different print moves are optimized against specific membranetensions.

In some embodiments, the data collected from the sensors and controlsystems becomes part of a permanent quality record for the partsproduced during the print job.

In some embodiments, information from more than one sensor is used inclosed loop feedback systems in PRPSs. Some examples of closed loopsystems in PRPSs employing more than one sensor are described above.Some additional examples of closed loop systems in PRPSs employing morethan one sensor will now be described.

In an example, thermal feedback from more than one sensor can beobtained and used to enable energy exposure adjustment in bulk and foreach spatially addressable element of the build area in PRPSs.Temperatures of the resin bath (e.g., taken at one or more points withinthe resin pool) can be monitored to detect changes in the bulk resintemperature. These changes can be used to make adjustments to theoverall (or maximum, or average) energy level of each print layerexposure to compensate for changes in the bulk resin reactivity as afunction of resin temperature. FIG. 4 shows an example energy graph withillumination energy on the y-axis and pixels (i.e., “print elements”)along the x-axis. The operating global energy level is shown as thedotted line 405, which is a reference point for all of the illuminationenergies in an image, wherein the illumination energy of each pixel isdetermined as an offset from the operating global energy level 405. Insome embodiments, the operating global energy level 405 can be adjustedas indicated by arrow 410 based on the bulk resin temperature.Additionally, thermal image feedback of local temperatures in the buildarea can be used in conjunction with the bulk temperature feedback tofine-tune the amount of energy being delivered to each spatiallyaddressable element of the build area. FIG. 4 shows an example wheredifferent pixels (e.g., 0, 1, 2, . . . ) are adjusted with differentcorrections on a per pixel basis (e.g., “Δe₁”, “Δe₂”, “Δe₃₋₅”, etc.)based on the information from the thermal imaging system. FIG. 4 showsan example where the amount of energy delivered to pixel 1 has beendecreased by an amount Δe₁ compared to the original (or unadjusted)pixel 1 energy level which was equal to that of pixel 0. The energydelivered to pixel 2 has been changed to new level e₂ (the pixel 2energy level before correction is not shown in the figure), and theenergy delivered to pixels 3-5 has been changed to a new level e₃₋₅ (thepixel 3-5 energy levels before correction are not shown in the figure).In another example, in a PRPS with an exposure resolution of 1920 by1080 pixels there are 2,073,600 unique spatially addressable elements inthe build area. Exposing specific regions of the build area to energycauses “local” thermal fluctuations (i.e., on the pixel length scale)within the resin pool. Since the reactivity of the resin is typicallydependent on temperature, these local temperature fluctuations caused bythe printing process of a layer directly influence the exposure of asubsequent layer, and the thermal interactions between adjacent layersduring printing can ultimately affect the end part quality. Variouscourses of action can be taken to mitigate this effect such as waitingfor a return to a spatially uniform thermal gradient. However, thisapproach would slow the print process potentially rendering it noteconomically viable. In some embodiments, the PRPSs described hereinovercome these problems by combining the feedback of the bulk resintemperature and the thermal image system in a closed loop system tocontinuously ensure that the energy level is optimized, both globallyand locally, for print speed and part quality. For example, as hot spotsdevelop in the build area the exposure energy levels for subsequentprinted layers can be reduced in those “hot” regions to maintain partbuild quality without introducing delays in the print process. In thismanner, closed loop feedback from both bulk and local temperaturemonitoring systems can be used to maintain maximum print speed withoutsacrificing build quality.

In some embodiments, the relationship between energy delivered to theresin and the cure depth (i.e., the degree to which the photopolymercures) are related by a function, and that function can have anyrelationship (e.g., linear, logarithmic, piece-wise continuous withoutan analytical expression, discrete, etc.). This relationship can be usedin a closed loop feedback for a PRPS, for example, to adjust the energydelivered to a given pixel based on a desired cure depth of the pixeland a measurement of the resin temperature in the vicinity of the pixel.

In some embodiments, the illumination source (e.g., lamp, LED array,laser, etc.) within the illumination system will age over time, causingthe amount of energy projected onto the print area to decrease overtime. In some embodiments, the PRPSs and methods described herein canaccount for the illumination system aging. In some cases, the lightoutput from the illumination system can be directly measured (e.g.,using a photosensor) over the lifetime of the illumination source. Inanother example, the bulk resin temperature and thermal imaging systemcan detect changes in resin temperature for a given amount of deliveredillumination energy, and if the temperature rise is less than expected(e.g., due to an aging illumination source), then the operating globalenergy level 405 can be changed to account for the discrepancy. In someembodiments, a PRPS can have a new light source within the illuminationsystem, and the operating global energy level 405 can be set at a lowerlevel (e.g., 80%). Then, as the illumination source within theillumination system ages, the operating global energy level 405 can beincreased (e.g., up to 90%, or 95%, or 100%) to keep the print qualityconsistent from run to run over the useful lifetime of the illuminationsource.

In another example, information from multiple sensors can be obtained,and used to determine the resin viscosity and predict maximum acceptableaccelerations and velocities of vertical elevator moves in PRPSs. In thefollowing example, information from two or more of the following sensorscan be used together: z-stage position, movement direction, velocity andacceleration, resin bulk temperature, resin tub down force, resin tubvertical displacement, and elevator arm load sensor. In this example,the information from the resin bulk temperature sensor, along with theinformation from one or more of the additional sensors listed above,will enable the system to determine the resin viscosity and predictmaximum acceptable accelerations and velocities of vertical elevatormoves. For example, the viscosity of the resin will impact the loadsexperienced by the print platform as it moves through the resin.However, the loads experienced by the print platform can also bedependent on the rate of movement of the print platform through theresin, and therefore the effective viscosity of the resin can be moreaccurately determined when feedback from multiple sensors (e.g.,including print platform velocity and acceleration sensors, and not onlybulk resin temperature sensors) are utilized. In some embodiments, thegeometry of a part being printed is taken into account when using theabove combinations of sensors and PRPS movements to determine resinviscosity.

The limits imposed on the maximum acceptable accelerations andvelocities of vertical elevator moves can be further enhanced byknowledge of the geometry that is currently being created at the polymerinterface. For example, large cross-sectional areas will increase thedamping effect of moving the part and the print tray through the resin,whereas smaller cross-sectional areas will reduce this effect. In thisexample, elevator arm load and resin tub vertical displacement feedbackcan be used in conjunction with the z-stage acceleration, position andvelocity feedback to understand additional system behavior during aprint run, and provide corrective actions in a closed loop feedbacksystem. For example, information from multiple of the sensors listedabove can be used to determine if the system is behaving as modeled, andif not, then the system can correct the z-stage movement profiles tobring the desired operating speeds and membrane loads back within normaloperating limits. Additionally, information from the sensors listedabove can indicate if there is any impending anomalous behavior that mayindicate the print process has failed, at which point the mosteconomical course of action could be to halt the print job to avoidwasted resources or possible equipment damage.

In another example, information from multiple sensors is integrated intoa closed loop feedback system in a PRPS to detect changing adhesionforces between the cured resin layer and the membrane. As these adhesionforces increase, the membrane could become deformed, or the printedlayer could adhere to the membrane and not release at all. In someembodiments, the flexible nature of the membrane produces inaccurate ordefective geometry in a printed layer as a result of radiant energyexposure when the polymer interface plane is at the wrong z-position.Detection and correction of such a situation using multiple sensors(e.g., z-stage position, movement direction, velocity and acceleration,resin bulk temperature, resin tub down force, resin tub verticaldisplacement, and elevator arm load sensor) can enable the print tocontinue without failure. In some cases, corrective actions can rangefrom slowing down the z-stage move speeds to maintain adhesion (ordelamination) loads within limits or pausing to allow the membrane andthe resin tub to return to the required steady state positions beforecontinuing the print job. Additionally, detection of adhesion loads andmembrane deflections that are lower than anticipated could provideopportunities to increase the printing process speed in a similarmanner.

In another example, a present PRPS can be equipped with an automaticresin dispensing system (e.g., system 1060 in FIG. 1M), containing anautomatic resin dispenser that dispenses resin from one or more resinvats to the resin tubs of one or more PRPSs. The resin vat(s) cancontain one or more sensors to measure the properties of the resin inthe resin vat(s), and the automatic resin dispenser can dispense resinfrom resin vat(s) only when the resin meets certain criteria. Forexample, the resin vat(s) can contain temperature sensors and viscositymeasurement systems (e.g., viscometers, or rheometers), and the resincan be dispensed only when the resin temperature and viscosity arewithin certain predetermined limits. A resin level sensor (e.g., element55 in FIG. 1C) can be used in the automatic resin dispensing system todetermine how much resin is in a given resin tub of a PRPS, and when aresin tub is full. Such an automatic resin dispensing system can alsoprovide information about leaks, such as a leak in the membrane, or ahose or other component within the PRPS and/or automatic resindispensing system, by comparing a predicted resin level in the resin tub(e.g., from a calibrated pump and/or dispense time) and the actual resinlevel from the resin level sensor. For example, if a membrane isleaking, then the resin level will be lower than expected, and thisinformation can be fed back to the automatic resin dispense system orother system in the PRPS (e.g., to send notifications to an operator).

In another example, information from environmental sensors near a PRPS(e.g., sensor 70 in FIG. 1L) can be used to adjust a print recipe duringa print run, or between print runs to improve the quality of the printedparts. The environmental sensors can acquire data from an entirefactory, and/or an enclosure containing one or more PRPSs. Somenon-limiting examples of environmental sensors are air pressure,temperature, humidity sensors, and “sniffer sensors” for detecting oneor more odors and/or chemicals. For example, the PRPS can useenvironmental air pressure and temperature sensor data to determine howlong to expose each layer, and/or over what distance to move the printplatform between printed layers.

In some embodiments, environmental sniffer sensors that are capable ofdetecting one or more odors and/or chemicals in the environment near aPRPS can be used to provide information to adjust a print recipe duringa print run, between print runs. For example, one or more sniffersensors can be used with environmental temperature sensors to determineif resin(s) are conditioned (e.g., mixed and/or heated) correctly priorto being used for printing. In such an example, the resin can emitdifferent smells (that are detectable by the sniffer sensors) atdifferent temperatures thereby enabling the ability to determine if theresin is ready to be used. Using the feedback from the sniffersensor(s), if the smell is not as expected, then additional heating andmixing can be applied before using the resin in a print run. Sniffersensors can also be used with temperature sensors as a safety system.For example, if the exposure from a projection system iscatastrophically stuck in a high-power setting causing an increase inthe temperature around the PRPS, and simultaneously causing a smell tobe emitted (e.g., a burnt smell) that is detectable by a sniffer sensor,then the information from these sensors can be fed back to the PRPS toabort the print run. Sniffer sensors and particle counter sensors canalso be used in combination to determine if local air quality near oraround the print engine is below a predetermined set of thresholds, andnotifications can be sent out or a print job can be gated if the airquality is inadequate.

In another example, a combination of accelerometers can be used todetect an external impact event that may exceed a pre-determined limitfor producing a part with an acceptable print quality. For example, acombination of g-force determined on the print chassis, vibration and/org-force detected on the print spine can be used. In some cases, nosingle measured value would exceed a failure threshold, but when valuesfrom multiple of the above sensors are taken in combination they canindicate that a failure criteria has been exceeded.

In another example, the factory/house air pressure (e.g., used forpneumatics in print engine systems) can be measured, and used to gatethe commencement of a print job. For example, if the house air pressureis too low, then the system will not allow a print job to take place,thereby saving resin and time spent on producing a part that may havelow quality. The system can also prevent a print job from occurring ifthe pressure is exceedingly high and capable of damaging components(e.g., pneumatic systems, membranes, tension rings, resin tubs, etc.).

In another example, elevator arm force (or load) sensor data can becorrelated to the expected movement of the z-stage. For example,programmed and actual (i.e., measured) z-stage motor current levels canbe compared to elevator arm force data, and if there is a discrepancy inthe actual versus the expected force on the elevator arms then the printrecipe can be adjusted during a print run (e.g., the print could beslowed down, the exposure times changed, etc.), or the print job can beaborted (to save resin and time). For example, such a force discrepancycould indicate a problem with either the print engine (motor subsystem,clutch engagement issues, mechanical issues, etc.) or a part beingprinted. Such a discrepancy could also indicate premature wear oncomponents/equipment, such as (but not limited to) lead screws andbearings.

In another example, a PRPS can perform an initial check to ensuresubsystems related to the elevator arms, membrane tension system and/ormotor are wired correctly by monitoring elevator arm force (or load)sensor data, or membrane tension system force sensor data, compared tocommanded motor direction. For example, if the system sees unexpectedforce (e.g., magnitude and/or direction) when it commands the motor tomove in a certain direction, it can then infer a problem with eithersubsystem (e.g., the elevator arms or motor system) and alert atechnician and/or operator to check the wiring in the PRPS. In anotherexample, the linear encoder system (e.g., elements 35 and 40 in FIG. 1B)can be used with the elevator arm force sensors to check the motorwiring.

In another example, one or more audible sensors (i.e., sensors capableof detecting sounds) coupled together with the elevator arms force(load) sensors can be used to determine the degree to which a printedpart is sticking (or adhering) to the membrane. A part that is stickingto the membrane can emit sounds indicative of the degree to which thepart is sticking to the membrane, and these sounds can be used in aclosed loop feedback system to adjust the print recipe during the printrun. For example, based on the stiction sound information from theaudible sensor(s) and force data from sensors (e.g., load cells) on theelevator arms, various print parameters can be adjusted in real time(e.g., slowing down movements, or adjusting pump moves in real-time) toachieve desired print quality.

In another example, the combination of an audible sensor coupledtogether with an accelerometer or vibration sensor can be used to detectPRPS equipment wear. For example, if the lead screw in the PRPS makes anoise during movement while vibrating the entire z-stage, then it can beinferred that the lead screw or drive mechanism is wearing out on theprint engine. In different embodiments, different noise signaturescoupled together with different vibration/accelerometer signatures canbe used to map to different wear points in the system.

In another example, airflow sensors and environmental temperaturesensors can be used to monitor cooling systems within the imageprojection systems and surrounding print engine environments. Forexample, if an airflow sensor reads a lack of flow for the imageprojection system(s) coupled with an increase in temperature nearby,then the system(s) can react to protect the equipment (the imageprojection system(s), in this case). For example, the PRPS could go intoa safe mode to protect against equipment overtempt conditions. Suchcooling systems can also be used in an enclosure containing severalPRPSs, and this cooling system can be controlled using the abovecombination of sensors.

In another example, feedback from one or more accelerometers and motorencoder sensor systems can be used to adjust movement velocities toavoid harmonics (i.e., mechanically resonant conditions) in the PRPS.

FIG. 5 is a flowchart of a method 500 for closed loop feedback in PRPSs,in accordance with some embodiments. In step 510, a PRPS is provided.The PRPS includes a chassis; an elevator system with elevator armsmovably coupled to the chassis; a print platform mounted to the elevatorarms; a resin tub; a membrane tension apparatus which applies a downwardforce on the resin tub; a resin pool confined by the resin tub and themembrane; an illumination system; a plurality of sensors; and a printrecipe. The resin tub of the PRPS comprises a membrane, and the membranerests on a physical tension element such that increasing downward forceon the resin tub induces increasing tension on the membrane. Theplurality of sensors includes a resin bulk temperature sensor, andoptionally a resin tub vertical displacement sensor and an elevator armload sensor. The print recipe comprises comprising information for eachlayer in a 3D printed part to be built on the print platform. The printrecipe comprises one or more of build geometry, illumination energy,exposure time per layer, wait time between layers, print platformposition, print platform velocity, print platform acceleration, resintub position, resin tub force, resin chemical reactivity, and resinviscosity.

In step 520 of method 500, an image is projected through the membraneand focused at a polymer interface located within the resin pool usingthe illumination system. In step 530, the print platform is moved in az-direction with the print platform velocity and the print platformacceleration using the elevator system. In step 540, a downward force isapplied to the resin tub to induce a membrane tension on the membrane.In step 550, a resin bulk temperature is measured using the resin bulktemperature sensor. In step 560, the print platform velocity and theprint platform acceleration in the print recipe are updated during aprinting run based on the resin bulk temperature of the resin pool.

In other embodiments, the plurality of sensors in the PRPS provided inmethod 500 comprises one or more of the following: a z-stage positionsensor; a z-stage velocity sensor; a resin tub vertical displacementsensor; an elevator arm load sensor; an accelerometer; a resin bulktemperature sensor; and a thermal imaging system. The PRPS provided inmethod 500 can additionally include any of the features of the PRPSembodiments described above (e.g., multiple image projectors, movingimage projectors, etc.).

FIG. 6 is a flowchart of a second method 600 for closed loop feedback inPRPSs, in accordance with some embodiments. Steps 510-560 are the sameas in the above method 500. In this method 600, the PRPS comprises theoptional resin tub vertical displacement sensor and elevator arm loadsensor. In step 610, a load on the elevator arm is measured using theelevator arm load sensor, and a resin tub vertical displacement ismeasured using the resin tub vertical displacement sensor. In step 620,the resin tub position and the resin tub force in the print recipe isupdated during a printing run based on the load on the elevator arm, theresin tub vertical displacement, and the bulk temperature of the resinpool.

The methods 500 and 600 are non-limiting examples. Other embodimentssimilar to these example methods include a PRPS comprising one or moreof the sensors described herein, using the sensors to perform one ormore measurements, and using the measurements to adjust one or moreelements of the print recipe described herein.

Reference has been made in detail to embodiments of the disclosedinvention, one or more examples of which have been illustrated in theaccompanying figures. Each example has been provided by way ofexplanation of the present technology, not as a limitation of thepresent technology. In fact, while the specification has been describedin detail with respect to specific embodiments of the invention, it willbe appreciated that those skilled in the art, upon attaining anunderstanding of the foregoing, may readily conceive of alterations to,variations of, and equivalents to these embodiments. For instance,features illustrated or described as part of one embodiment may be usedwith another embodiment to yield a still further embodiment. Thus, it isintended that the present subject matter covers all such modificationsand variations within the scope of the appended claims and theirequivalents. These and other modifications and variations to the presentinvention may be practiced by those of ordinary skill in the art,without departing from the scope of the present invention, which is moreparticularly set forth in the appended claims. Furthermore, those ofordinary skill in the art will appreciate that the foregoing descriptionis by way of example only, and is not intended to limit the invention.

What is claimed is:
 1. A photoreactive 3D printing system, comprising: achassis; an elevator system movably coupled to the chassis, wherein theelevator system comprises elevator arms; a print platform mounted to theelevator arms; a resin tub attached to the chassis, wherein the resintub comprises a membrane, and the membrane rests on a physical tensionelement such that an increasing downward force on the resin tub inducesan increasing tension on the membrane; a membrane tension apparatuswhich applies a downward force on the resin tub; a resin pool confinedby the resin tub and the membrane; an illumination system; a pluralityof sensors comprising at least two of: a z-stage position sensor; az-stage velocity sensor; a resin tub vertical displacement sensor; anelevator arm load sensor; an accelerometer; a resin bulk temperaturesensor; and a thermal imaging system; and a print recipe comprisinginformation for layers in a 3D printed part to be built, wherein theprint recipe comprises one or more of build geometry, illuminationenergy, exposure time per layer, wait time between layers, printplatform position, print platform velocity, print platform acceleration,resin tub position, resin tub force, resin chemical reactivity, andresin viscosity, wherein the print recipe is updated during a printingrun based on input from at least two sensors of the plurality ofsensors, and wherein the print recipe is updated based on input from thethermal imaging system by updating the illumination energy in aplurality of pixels, wherein the illumination energy for each pixel isadjusted individually.
 2. The photoreactive 3D printing system of claim1, wherein the membrane tension apparatus comprises pneumatic cylinders.3. The photoreactive 3D printing system of claim 1, wherein the membranetension apparatus comprises motors and linear encoders.
 4. Thephotoreactive 3D printing system of claim 1, wherein the illuminationsystem comprises at least one of a light emitting diode, a liquidcrystal display, and a laser.
 5. The photoreactive 3D printing system ofclaim 1, wherein the illumination system moves during the printing run.6. The photoreactive 3D printing system of claim 1, further comprisingmore than one illumination system, wherein the more than oneillumination systems are configured in an array.
 7. The photoreactive 3Dprinting system of claim 1, wherein: the thermal imaging systemcomprises a hot mirror and a thermal imaging camera; the hot mirror isaligned with an optical axis of the illumination system; and the hotmirror is angled such that the thermal imaging camera captures imagesreflected by the hot mirror.
 8. The photoreactive 3D printing system ofclaim 1, wherein the accelerometer monitors physical movement of the 3Dprinting system during the printing run, and sends a signal to abort theprinting run if an acceleration is detected above a predeterminedthreshold.
 9. A photoreactive 3D printing system, comprising: a chassis;an elevator system movably coupled to the chassis, wherein the elevatorsystem comprises elevator arms; a print platform mounted to the elevatorarms; a resin tub attached to the chassis, wherein the resin tubcomprises a membrane; a resin pool confined by the resin tub and themembrane; an illumination system; a plurality of sensors comprising aresin bulk temperature sensor and a thermal imaging sensor; and a printrecipe comprising information for layers in a 3D printed part to bebuilt, wherein the print recipe comprises one or more of build geometry,illumination energy, exposure time per layer, wait time between layers,print platform position, print platform velocity, print platformacceleration, resin tub position, resin tub force, resin chemicalreactivity, and resin viscosity, wherein: the print recipe is updatedduring a printing run based on input from the resin bulk temperaturesensor and the thermal imaging sensor; and the print recipe is updatedby updating the illumination energy in a plurality of pixels, whereinthe illumination energy for each pixel is adjusted individually.
 10. Thephotoreactive 3D printing system of claim 9, further comprising a resincirculation system, wherein the resin circulation system comprises pumpsto flow the resin in and out of the resin tub.
 11. The photoreactive 3Dprinting system of claim 9, wherein the resin tub further comprisessolid state cooling.
 12. The photoreactive 3D printing system of claim9, further comprising: a resin vat; an automatic resin dispensing systemhaving an automatic resin dispenser that dispenses resin from the resinvat to the resin tub; and a resin level sensor to measure an amount ofresin in the resin tub.
 13. The photoreactive 3D printing system ofclaim 12, wherein the resin level sensor further measures a rate ofchange of the amount of resin in the resin tub over time.
 14. Thephotoreactive 3D printing system of claim 9, wherein: the plurality ofsensors further comprises: a resin level sensor to measure an amount ofresin in the resin tub and to measure a rate of change of the amount ofresin in the resin tub over time; and an elevator arm load sensor tomeasure an amount of load experienced by the print platform; and theplurality of sensors provides information about if the part hasdelaminated from the print platform.
 15. The photoreactive 3D printingsystem of claim 9, further comprising a z-stage comprising anelectro-mechanical system providing motion to the elevator system,wherein: the plurality of sensors further comprises: an elevator armload sensor; and one or more of a z-stage position sensor and a z-stagevelocity sensor; and the plurality of sensors provides information aboutthe resin viscosity by measuring the print platform position, printplatform velocity and a load experienced by the print platform as it ismoved through the resin pool.
 16. The photoreactive 3D printing systemof claim 15, wherein: the information from the plurality of sensors isused to determine the resin viscosity; the print recipe furthercomprises a maximum print platform velocity and a maximum print platformacceleration; and the resin viscosity determined from the information isused to update the maximum print platform velocity and the maximum printplatform acceleration.
 17. The photoreactive 3D printing system of claim9, wherein the illumination energy for each pixel in the print recipe isupdated based on a relationship between energy delivered to the resinand a cure depth.
 18. The photoreactive 3D printing system of claim 9,wherein the resin bulk temperature sensor and the thermal imaging sensordetect changes in resin temperature for a given amount of deliveredillumination energy, and update the illumination energy to account forany discrepancies.
 19. The photoreactive 3D printing system of claim 9,wherein: the photoreactive 3D printing system further comprises az-stage comprising an electro-mechanical system providing motion to theelevator system; the plurality of sensors further comprises: a z-stageposition sensor; and an elevator arm load sensor; and the plurality ofsensors provides information about adhesion forces between a cured resinlayer and the membrane by measuring the position and load experienced bythe print platform as it is moved away from the membrane between layerexposures.
 20. The photoreactive 3D printing system of claim 19, whereinthe plurality of sensors further comprises a z-stage velocity sensor ora z-stage acceleration sensor.
 21. The photoreactive 3D printing systemof claim 9, wherein the plurality of sensors further comprises one ormore of a radiant power sensor, a plurality of resin bulk temperaturesensors, a z-stage position sensor, a z-stage velocity sensor, anelevator arm load sensor, and an accelerometer.
 22. The photoreactive 3Dprinting system of claim 9, wherein data is collected from the pluralityof sensors and is incorporated in a permanent quality record.